Volkswagen New Beetle. Manual - part 2522

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The ends -A- of the springs are bended from the transmission date indicated above. 

The changed springs are installed on both sides. 

Fig. 99: Installing Changed Springs 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

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The changed springs can be installed in previous transmissions only with locking pieces, which are inner 
hollow.  

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Inserting lock pieces (installation position: See 5th gear synchronizer ).  

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Installation position of the springs:  

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Insert springs offset by 120°.  

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The spring must secure with the angled end -A- in the hollow lock piece. 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 100: Locating Installation Position Of Springs 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

The spring must be under the lug -B- from the locking piece.

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

The bended end points always from synchronizer body (direction of arrow).

INPUT SHAFT, ADJUSTING 

(Determining input shaft adjustment shim) 

Special tools and equipment 

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VW 387 Universal dial gauge bracket  

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VW 385/17 End measuring plate  

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VW510 Press piece  

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VW 447 i Thrust plate  

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VW 407 Press tool  

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V.A.G 1331 Torque wrench  

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Measuring dial gauge 

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle

  

Fig. 101: Identifying Special Tools And Equipment 
Courtesy of VOLKSWAGEN OF AMERICA, INC. 

It is necessary to readjust the input shaft when the following components are replaced:  

 

2003 Volkswagen New Beetle GLS 

1998-2004 TRANSMISSION 5 Spd. Manual Transmission 02J - New Beetle